Blind shims for pre-fit door units



pril 29, 1969 M. 1 HUGHES' 3,440,783

BLIND SHIMS FOR PRE-FIT DOOR UNITS A Filed July s, 19e? sheet of 2 FIGA` F162 Toe/Var April 29, 1969 M. L. HUGHES 1440783 BLIND SHIMS FOR PRE-FIT DOOR UNITS Filed July s, 1967 Sheet ,2 of 2 F'QLL/f FIG 8 FIG. I

. INVENTOR. MH. 70N L Ilz/H55 FIGJI im? United States Patent O U.S. Cl. 52-213 6 Claims ABSTRACT F THE DISCLOSURE The present invention teaches different types of blind shims for use with pre-fit door units wherein the door jamb and casing are precut and preassembled. The subject blind shims are generally U-shaped to conform to the door jamb and side casings, and are formed of sheet metal or plastic. They are further formed with offset portions for engaging the door jamb so that the shims provide additional strength and support therefor. Such offset portions tit within corresponding slots in the door jamb and the shim is anchored in place by nails driven through the side casings and shim into the door frame.

The present invention relates generally to blind shims for pre-fit door units and, more particularly, to shims for use in affording additional support for door units following mounting thereof.

Within the past several decades, new manufacturing methods and procedures have been incorporated in virtually all industries. The construction industry is no exception since many time-saving innovations have been incorporated in the construction operations of homes, office and industrial buildings.

One such advance over prior methods of construction has been the pre-fit door units whereby the door jamb and casings are preassembled and cut t0 proper length at the factory. They are then installed within the rough door opening with minimum time and effort on the part of the assembling workman.

Such new method is to be contrasted with the procedure heretofore employed wherein the jambs and casings were transported to the job site or building in random lengths. They were then cut and fitted in place by highly skilled workmen to insure that all of the corners were properly formed and the door opening was of proper size.

The present use of pre-tit door units, however, enables a home purchaser to receive an exceptionally good work product at minimum cost.

The use of pre-fit units, however, has created certain problems. For instance, whereas previously the workman was able to use wooden shims between the door jamb and the door frame, this is no longer possible due to the fact that the pre-fit units render such area inaccessible. That is, prior shims were wedge-shaped, and by using several of them in opposed relation, it was possible to provide substantially any desired thickness of support for the door jamb. Such shims were easy to install between the jamb and frame member since there was suicient access at the sides thereof due to the absence of the side casings. Now, however, with the use of pre-t units, such access is no longer available.

It is an object of the present invention to provide blind shims for use with pre-fit door units for supporting a door jamb in proper spaced relation to .a door frame member.

Another object of the present invention is to provide blind shims for use with pre-lit door units as characterized above wherein such shims rmly engage both the jamb and the frame member to firmly support them in relative position.

Another object of the present invention is to provide blind shims for use with pre-fit door units as characterized 3,440,783 Patented Apr. 29, 1969 above which can be adjusted Iafter installation of the pret units to enable workmen to provide the desired. door openlng.

A still further object of the present invention is to provide blind shims for use with pre-fit door units as characterized above which are firmly anchored in place by the usual finishing nails or brads employed in fastening the side casing or molding in place.

An even further object of the present invention is to provide blind shims for use with pre-fit door units which comprise means for firmly engaging the door frame so as to urge the door units into proper relation.

Another object of the present invention is to provide blind shims for use with pre-fit door units as characterized above which are simple and inexpensive to manufacture and which are rugged and dependable in operation.

The novel features which I consider characteristic of my invention are set forth with particularity in the appended claims. The device itself, however, both as to its organization and mode of operation, together with additional objects and advantages thereof, will best be understood from the following description of specific embodiments when read in connection with the accompanying drawings in which:

FIGURE 1 is a perspective view of a pre-fit door unit, partially installed;

FIGURE 2 is a similar perspective view of a pre-fit door unit, installed;

FIGUR-E 3 is a fragmentary sectional view of a corner of the pre-fit door unit of FIGURE 1;

FIGURE 4 is a similar fragmentary sectional view of a corner of the unit of FIGURE 2;

FIGURE 5 is a side elevational view of a pre-fit door section showing alternate locations for shims;

FIGURE 6 is a fragmentary sectional view, taken substantially along line 6 6 of FIGURE 3;

FIGURE 7 is a fragmentary elevational view, taken substantially along line 7-7 of FIGURE 3;

FIGURE 8 is a fragmentary sectional view, taken Substantially along line 8-8 of FIGURE 7;

FIGURE 9 is a sectional View, taken substantially along line 9-9 of FIGURE 4;

FIGURE 10 is a fragmentary elevational view of another embodiment of the present invention;

FIGURE l1 is a transverse sectional view, taken substantially along line 11-11 of FIGURE 10;

FIGURE 12 is a fragmentary elevational view of an additional embodiment of the present invention; and

FIGURE 13 is a fragmentary sectional view, taken substantially along line 13-13 of FIGURE l2.

Like reference characters indicate corresponding parts throughout the several lviews of the drawings.

Referring to FIGURE 1 of the drawings, there is shown therein a pre-fit door unit 16 partially installed Within a rough door opening 18 of a Wall 20. Such opening is formed in the usual manner and is defined by a door frame consisting of frame members one of which is shown at 22. Plaster 24 is provided on opposite sides of the frame as shown in FIGURES 6 and 9.

Each pre-tit door unit 16 consists of a horizontal section 26 and a pair of vertical sections 27 and 28. As also most clearly shownv in FIGURE 6 of the drawings, each such horizontal land vertical section consists of a door jamb 30 to which is attached side casings 32 and 34. Each such jamb and side casings are firmly assembled at the factory by appropriate automatic machinery. Such individual sections are precut to the proper length in accordance with the size and shape of door to be installed. Included in such precutting is the formation of the mitered corners as shown at 36.

In order to install the pre-fit units to the ydoor frame,

the horizontal, overhead section 26 is first fastened in place. This section is installed around the horizontal frame member an-d the plaster on either side thereof. -It is placed the proper distance from the fioor in accordance with the size of the door to be employed, and is firmly secured in such position by finishing nails driven through the casing and plaster into the horizontal frame member. As will hereinafter be explained in greater detail, the subject blind shim is usable to properly support the horizontal section 26. However, the construction, installation and operation of such shims will be `described in reference to vertical section 28.

After the horizontal door section 26 is in place, the vertical section 27 is fixed in its proper position. Thereafter, the vertical section 28 is inserted at an angle at the top adjacent section 26, to permit the lower portion thereof to be pushed into proper position against the door frame as indicated by the arrow 38. This particular method is employed to insure that the corners of the pre-fit unit are firmly pulled together.

Hcretofore, the installer has partially driven several nails into the vertical frame member 22 near the top of the rough door opening to thus provide means whereon the pre-fit section 28 can be pivoted to close the corners as the bottom of section 28 is moved into position. Such nails, of course, were necessary due to the fact that the general cross-section of the pre-fit door sections is U- shaped thus providing an inaccessible space between the door frame member and the jamb.

As shown most clearly in FIGURES 3, 4 and 6 of the drawings, the present invention provides a shim 40 for use in such blind location. Such shim is formed of sheet metal or plastic and is provided with a general U-shape, having an intermediate portion 40a and a pair of side portions 40h and 40C. The intermediate portion 40a is intended to abut the door jamb 30 whereas the side portions 40b and 40o abut the side casings 32 and 34, respectively.

The intermediate portion 40a of shim 40 is formed with several cutouts or tabs 40d and 40e which are generally tapered to provide sharp piercing points as at 40j and 40g. Each such tab is bent inwardly of the U-shape construction to be parallel with the side portions 4011 and 40e` to pierce or engage the door frame member 22 as will hereinafter be explained.

It is contemplated that the blind shim 40 may be formed in substantially a single punching-forming operation in a suitable press. In this manner, such shim can be made inexpensively by mass production methods.

As shown most clearly in FIGURE 3 of the drawings, the blind shim 40 is placed against the frame member 22 and is tapped firmly to cause the points 40)c and 40g of the tabs 40d and 40e to engage slightly said frame member 22. Thereafter, the pre-fit section 28 is pivoted in a clockwise manner as shown in FIGURE 1, the door jamb 30 resting against such shim 40 as shown most clearly in FIGUR-E 3. This firmly forces the corners 36 together and, if the horizontal pre-fit section 26 has been cut to proper length, the desired door opening is provided. It should be noted that throughout such installation, the shim 40 may be urged farther into the door frame member 22 in accordance with the relationship between the various pre-fit sections.

It is also desirable, if not necessary, to provide means for anchoring such door sections 26, 27 and 28 to the respective frame members. Since there is a space or opening between the door jamb and the corresponding door frame, it is desirable to provide a shim therebetween to provide the desired strength. To this end, the blind shim 50 is provided, as shown most clearly in FIGURES 3, 4, 7, 8 and 9.

Shim 50 comprises an intermediate portion 50a a-nd side portions 50b and 50c. The upper edge 50d of the interimediate portion extends beyond the upper extremity of theY side portions 50b and 50c and is bent outwardly at an angle approximating that shown in FIGURE 8.

The corresponding door jamb 30 is formed with a cutout or groove 30a which extends the entire width of the jamb. In order to assemble the shim 50 with the jamb 30, the angularly bent edge 50d is inserted into the slot 30a. The enti-re pre-fit section is then placed around the door frame -member 22 and plaster surfaces on either side thereof, the side portions 50b and 50c being positioned between such plaster and the side casings 32 and 34, respectively.

It should be noted that the angularly bent upper edge 50d of the intermediate portion 50a of shim 50 holds the shim in place by virtue of its interlocking engagement with the slot 30a of jamb 30. Once the pre-tit section and shim are thus assembled, it is a simple matter for the installer to nail the side portions 50b and 50c to the frame member 22 by the use of finishing nails 51 as shown in FIGURE 9. In addition, it is possible to provide further strength to the shim by nailing through the jamb 30 and intermediate portion 50a into frame member 22.

It should be particularly noted that the interlocking engagement of edge 50d and slot 30a provides continuing strength and stiffness for preventing warping or buckling of the door jamb 30. In this regard, the fact that the edge 50d engages the slot 30a substantially throughout the entire width of jamb 30 effectively eliminates buckling or warping along a horizontal plane.

FIGURE 5 shows a plurality of slots 30a at each of several locations to provide a choice in the placement of the blind shim 50.

FIGURES 10 and 11 disclose a second embodiment of the invention shown Iin detail in FIGURES 7, 8 and 9. Such second embodiment is a blind shim 52 having an intermediate portion 52a and side portions 52b and 52C. R'ather than having the aforedescribed angularly disposed up'per edge `50a as in the embodiment shown in FIGURES 7, 8 and 9, the blind shim 52 includes a pair of horizontally offset vertically disposed tabs 52d and 52e. Such tabs, as shown most clearly in 'FIGURE 11, are offset from the intermediate portion 52a in a direction opposite to the side portions 52b and 52C.

The door jamb 54 for receiving the fblind shim 52 is formed `with 'a pair of angularly disposed slots 54a and 54b which extend the entire length thereof. Thus, the appropriate number of iblind shims 52 can be assembled to the particular jamb 154 prior to installation of the door section to the fparticular door frame. Tabs 52d and 52e retain the yintermediate portion 52a of shim 52 in firm adjacent relation to the door jamb 54.

As 'above described with respect to the embodiment of FIGURES 7, 8 and 9, once the pre-fit section is pro- .vided with the blind shims 52, the entire section is placed about the frame member and plaster on either side thereof. Finishing nails as shown at 51 are then `driven throu'gh the side casings, side portions 52b and '52e of shim l52, the plaster, and the frame member.

FIGURES l2 and 13 show Ianother embodiment of the present invention.

In Ithe use of pre-fit door units the plaster is initially applied to the frame members so that the pre-fit and pre-assembled unit can t thereover. Thus, the jamb and side casings a-re Iinstalled in sections after the finishplastering operation.

In the installation of door jambs and casings separately, a ydifferent procedure is followed. Under these circumstances, the jamb is fixed in pl-ace initially, and thereafter the plastering is completed, flush with the opposite edges of the door jamb. Thereafter, the side casings are nailed in place providing a finished product with the door jamb.

Although all of the above explained embodiments of the present invention are susceptible of various changes and modifications in accordance with the particular result to be accomplished, the embodiment of FIGURES 12 and 13 is shown yin relation to the nonpre-t procedure.

Referring to FIGURE 13 of the drawings, it is seen that the wall structure includes a frame member 56 which, together with other frame members, defines the rough door opening. A door jamb 58 is to be fixed in place initially so that the plaster can be provided on either side of frame member 56 and ultimately the desired casings can be affixed thereto.

To accomplish the aforementioned procedure, the shim 60 is provided. Such shim comprises an intermediate p0rtion 60a as well as side portions 60b and 60C. The side portions, it will be seen in FIGURE 13, straddle the frame member 56 to enable construction nails 62 to be used to hold such shim in proper position.

The intermediate portion of shim 60 -is provided with an elongated upper edge 60d which extendsbeyond side portions 6017 Iand 60e. This affords maximum support for the door jamb 58 by extending substantially the entire width thereof. This feature is particularly desirable in the nonpre-ft construction because the side portions `60h and 60C are necessarily in closer proximity due to the lack of plaster.

The edge 60d of intermediate portion 60a is also angularly disposed as above-explained with respect to the upper edge 50d of shim 50. It is inserted within an appropriate slot or groove formed in the jamb 58. Thus, a r-igid connection is afforded therebetween as above explained with respect to shim 50.

After the door jamb is properly positioned as shown in FIGURE 13, the plaster is provided on either side of the wall. The finish molding or casings are then nailed in place to provide the finished product.

Although I have shown and described certain specific embodiments of my invention, I am fully aware that many modifications thereof are possible. My invention, therefore, is not to be restricted except insofar as is necessitated by the prior art and by the spirit of the appended claims.

I claim:

1. A preassembled door unit, comprising in combination, a door jamb and side casings therefor connected thereto as a unitary structure for at least partial encirclement of a door frame member, a fulcrum member formed of sheet material with a generally U-shaped body forming a pair of substantially parallel side tabs interconnected with a web, said U-shaped body fitting within said jamb and side casings and being further formed with at least one projection extending inwardly of the U-shape from said web for engagement with said frame member near one end thereof to constitute a fulcrum about which said door unit pivots during installation, said door jamb being formed with at least one groove along the inner face thereof, and a blind shim and support member formed of sheet material with a generally U-shaped body forming a pair of substantially parallel nailing tabs interconnected with a web, said U-shaped body fitting within said jamb and side casings and being further formed with an extension projecting from said web, said extension being fitted within said groove whereby said unit may be positioned about said frame member and fastening means may be inserted through said side casings, tabs and into said frame member.

2. A preassembled door unit comprising in combination, a door jamb and side casing therefor connected thereto as a unitary structure for at least partial encirclement of a door frame member, said door jamb being formed with at least one angular groove along the inner face thereof, and a blind shim and support member formed of sheet material with a generally U-shaped body forming a pair of substantially parallel nailing tabs interconnected with a web, said U-shaped body fitting within said jamb and side casings and being further formed with an angular extension projecting from said web, said extension being fitted within said groove whereby said unit may be positioned about said frame member and fastening means may be inserted through said side casings, tabs and into said frame member.

3. A preassembled door unit according to claim 2, wherein said angular groove along the inner face of said jamb is formed substantially transversely of said jamb, and said extension projecting from said web of said shim is formed along a marginal edge thereof between said nailing tabs.

4. A preassembled door unit according to claim 2, wherein said angular groove in said jamb is formed longitudinally thereof, and said extension on said lweb projects along a plane at right angles to the plane of the U-shaped configuration o-f said shim to project into said longitudinal groove.

5. A preassembled door unit, comprising in combination, a door jamb and side casing therefor connected thereto as a unitary structure for at least partial encirclement of a door frame member, a fulcrum member formed of sheet material with a generally U-shaped body forming a pair of substantially parallel side tabs interconnected with a web, said U-shaped body fitting within said jamb and side casings and being further formed with at least one projection extending inwardly of the U-shape from said web for engagement with said frame member near one end thereof to constitute a fulcrum about which said door unit pivots during mounting, whereby said unit may be positioned about said frame member and fastening means may be inserted through said side casing, tabs and into said lframe member.

6. A preassembled door unit according to claim 5, wherein said extension is struck vfrom said web to have a taper providing a relatively sharp point for insertion to any desired depth into said door frame to position said iunit relative to said frame.

References Cited UNITED STATES PATENTS 2.346,264 4/ 1944 Marshall 52-211 2,742,117 4/ 1956 Tolman 52--213 3,222,833 12/1965 Woodrum 52-211 3,184,800 5/1965 Nelson 52-714 X FRANK L. ABBOTT, Primary Examiner.

S. D. BURKE, Assistant Examiner.

U.S. Cl. X.R. 

